Suspension packaging

ABSTRACT

A suspension package insert ( 100 ) is disclosed comprising a suspension pouch ( 101 ) configured to receive an article therein. The suspension pouch ( 101 ) is formed of at least a first flexible suspension panel ( 103 ) and a second suspension panel ( 105 ) under the first flexible suspension panel ( 103 ), a first sidewall structure ( 107 ) attached to a first side of the suspension pouch, and a second sidewall structure ( 109 ) attached to a second side of the suspension pouch. The first and second sidewall structures ( 107, 109 ) are configured to stand and suspend the suspension pouch ( 101 ) therebetween.

FIELD

This disclosure relates to packages, more specifically to packaging,e.g., suspension packaging.

BACKGROUND

Certain article benefit from suspension packaging that creates an aircell inside an outer package to suspend a product within the package.Traditional suspension packaging utilizes a flexible plastic linerattached to a structure to suspend the article.

Such conventional methods and systems have generally been consideredsatisfactory for their intended purpose. However, there is still a needin the art for improved suspension packaging. The present disclosureprovides a solution for this need.

SUMMARY

A suspension package insert can include a suspension pouch configured toreceive an article therein. The suspension pouch can be formed of atleast a first flexible suspension panel and a second suspension panel, afirst sidewall structure attached to a first side of the suspensionpouch, and a second sidewall structure attached to a second side of thesuspension pouch. The first and second sidewall structures can beconfigured to stand and suspend the suspension pouch therebetween.

The first flexible suspension panel can include a cut matrix definedtherein configured to increase the flexibility of the first flexiblepanel. The second suspension panel can be uncut and/or is otherwise lessflexible than the first flexible suspension panel.

The suspension package insert can be made of a fiber material. Forexample, the fiber material can be paper. Any other suitable material iscontemplated herein.

In accordance with at least one aspect of this disclosure, a blank canbe configured to form a suspension package insert as disclosed herein(e.g., as described above). In accordance with at least one aspect ofthis disclosure, a blank for a suspension package insert can include afirst portion and a second portion foldably connected to the firstportion. The first portion and the second portion can be configured tobe attached together to form a suspension pouch and a sidewall assemblyto suspend the suspension pouch.

The first portion can include a first flexible suspension panel having acut matrix defined therein to increase a flexibility of the firstflexible suspension panel. The first portion can include a first sidepanel and a second side panel foldably connected to the first flexiblesuspension panel.

The first portion can include a first end panel and a second end panelfoldably connected to the first flexible suspension panel. The firstportion can include a plurality of first end corner panels and aplurality of second end corner panels foldably connected to a respectiveend panel and a respective side panel.

The second portion can include a second suspension panel. The secondportion can include a first side panel and a second side panel foldablyconnected to the second suspension panel.

The second portion can include a first end panel configured to foldrelative to the second suspension panel. The second portion can includea second end panel foldably connected to the second suspension panel.

The second portion can include an opening disposed between the first endpanel of the second portion and the second suspension panel. The secondportion can include a plurality of first end corner panels and secondend corner panels foldably connected to a respective end panel of thesecond portion and a respective side panel of the second portion. Thefirst end panel of the second portion can be foldably connected to thefirst and second side panels of the second portion via the first endcorner panels of the second portion.

The second portion can include a first extension side panel foldablyconnected to the first side panel of the second portion and a secondextension side panel foldably connected to the second side panel of thesecond portion. The first and second extension side panels can be eachtwice as wide as the first and second side panels of the second portion,respectively.

The second end panel of the second portion can be foldably connected tothe second end panel of the first portion. Additionally and/oralternatively, the second end corner panels of the second portion can befoldably connected to the second end corner panels of the first portion.

These and other features of the embodiments of the subject disclosurewill become more readily apparent to those skilled in the art from thefollowing detailed description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those skilled in the art to which the subject disclosureappertains will readily understand how to make and use the devices andmethods of the subject disclosure without undue experimentation,embodiments thereof will be described in detail herein below withreference to certain figures, wherein:

FIG. 1 is a perspective view of an embodiment of a suspension packaginginsert in accordance with this disclosure, shown being placed in a box;

FIG. 2 is a plan view of an embodiment of a blank in accordance withthis disclosure; and

FIGS. 3A-3H show the blank of FIG. 2 being assembled into the suspensionpackaging insert of FIG. 1 .

DETAILED DESCRIPTION

Reference will now be made to the drawings wherein like referencenumerals identify similar structural features or aspects of the subjectdisclosure. For purposes of explanation and illustration, and notlimitation, an illustrative view of an embodiment of a suspensionpackaging insert in accordance with the disclosure is shown in FIG. 1and is designated generally by reference character 100. Otherembodiments and/or aspects of this disclosure are shown in FIGS. 2-3H.Certain embodiments described herein can be used to provide suspensionpackaging using a single, semi-rigid material (e.g., a paper blank).

Referring to FIGS. 1-3H, a suspension package insert 100 can include asuspension pouch 101 configured to receive an article therein. Forexample, the suspension pouch 101 can be open on one end or both ends toallow insertion of a product into the pouch 101. The suspension pouch101 can be formed of at least a first flexible suspension panel 103 anda second suspension panel 105 under panel 103 in FIG. 1 ).

The suspension pouch 101 can include a first sidewall structure 107 aattached to a first side of the suspension pouch 101. The suspensionpouch 101 can include a second sidewall structure 109 attached to asecond side of the suspension pouch 101. The first and second sidewallstructures 107, 109 can be configured to stand and suspend thesuspension pouch 101 therebetween.

The first flexible suspension panel 103 can include a cut matrix 111defined therein configured to increase the flexibility of the firstflexible panel 103. For example, the first flexible panel 103 can be apaper panel of a blank that would otherwise be semi-rigid. Having a cutmatrix (e.g., and array of cuts in any suitable pattern or array) allowsthe semi-rigid material to flex (e.g., similar to a hammock).

In certain embodiments, the second suspension panel 105 can be uncutand/or is otherwise less flexible than the first flexible suspensionpanel. For example, the second suspension panel 105 can be a flat uncut,continuous sheet (e.g., of paperboard or other suitable material).

The suspension package insert 100 can be made of a fiber material. Forexample, the fiber material can be paper. For example, in certainembodiments, the insert 100 can be made of paperboard, corrugate, and/orany other suitable sheet material. Any other suitable material iscontemplated herein.

In accordance with at least one aspect of this disclosure, referring toFIG. 2 , a blank, e.g., 200, can be configured to form a suspensionpackage insert as disclosed herein (e.g., insert 100 as describedabove). In accordance with at least one aspect of this disclosure, ablank 200 for a suspension package insert, e.g., 100, can include afirst portion 100 a and a second portion 100 b foldably connected to thefirst portion 100 a. The first portion 100 a and the second portion 100b can be configured to be attached (e.g., glued) together to form asuspension pouch 101 and a sidewall assembly (e.g., 107, 109) to suspendthe suspension pouch 101 (e.g., such that the suspension pouch 101 isonly supported at a plurality of its sides by the sidewall assembly asshown in FIG. 1 ).

The first portion 100 a can include a first flexible suspension panel103 having a cut matrix 111 (e.g., a die-cut matrix) defined therein toincrease a flexibility of the first flexible suspension panel 103. Thecharacteristics and/or arrangement of cuts can define the rigidity ofthe first flexible suspension panel 103. For example, if the cuts of aconstant size are spaced out more, the suspension panel 103 will be morerigid. A type, size of cuts (length and/or width), and/or cut shape canbe modified to achieve a desired rigidity. In certain embodiments, atshape of the cut matrix 111 can be shaped to match a profile of aproduct (e.g., bottle shaped for a bottle). The individual cuts can beany suitable shape (e.g., a Y-shape as shown, T-shape, curve shape,etc.). The cut matrix 111 can be formed in the first suspension panel103 in any suitable manner (e.g., die cutting).

The first portion 100 a can include a first side panel 107 a and asecond side panel 109 a foldably connected (e.g., at a fold line asshown) to the first flexible suspension panel 103. The first portion 100a can include a first end panel 113 a and a second end panel 115 afoldably connected (e.g., at a fold line as shown) to the first flexiblesuspension panel 103. The first portion 100 a can include a plurality offirst end corner panels 117 a, 119 a and a plurality of second endcorner panels 121 a, 123 a foldably connected (e.g., at a fold line asshown) to a respective end panel 113 a, 115 a and a respective sidepanel 107 a, 109 a (e.g., as shown).

The second portion 100 b can include a second suspension panel 105. Thesecond portion 100 b can include a first side panel 107 b and a secondside panel 109 b foldably connected (e.g., at a fold line as shown) tothe second suspension panel 105.

The second portion 100 b can include a first end panel 113 b configuredto fold relative to the second suspension panel 105. The second portion100 b can include a second end panel 115 b foldably connected (e.g., ata fold line as shown) to the second suspension panel 105.

The second portion 100 b can include an opening 125 disposed between thefirst end panel 113 b of the second portion 100 b and the secondsuspension panel 105. The opening 125 can form the opening to the pouch101 when the blank 200 is assembled into a suspension pouch, e.g., 100for example.

The second portion 100 b can include a plurality of first end cornerpanels 117 b, 119 b and second end corner panels 121 b, 123 b foldablyconnected (e.g., at a fold line as shown) to a respective end panel 113b, 115 b of the second portion 100 b and a respective side panel 107 b,109 b of the second portion 100 b (e.g., as shown). As shown, the firstend panel 113 b of the second portion 100 b can be foldably connected tothe first and second side panels 107 b, 109 b of the second portion 100b via the first end corner panels 117 b, 119 b of the second portion 100b.

The second portion 100 b can include a first extension side panel 127foldably connected (e.g., at a fold line as shown) to the first sidepanel 107 b of the second portion 100 b. The second portion 100 b caninclude a second extension side panel 129 foldably connected (e.g., at afold line as shown) to the second side panel 109 b of the second portion100 b. In certain embodiments, the first and second extension sidepanels 127, 129 can be each twice as wide as the first and second sidepanels 107 b, 109 b of the second portion 100 b, respectively (e.g.,which can allow the suspension pouch 101 to be centered between ends ofthe sidewall structures 107, 109). Any other suitable dimensions arecontemplated herein.

The second end panel 115 b of the second portion 100 b can be foldablyconnected (e.g., at a middle fold line 131 as shown) to the second endpanel 115 a of the first portion 100 a. Additionally and/oralternatively, the second end corner panels 121 b, 123 b of the secondportion 100 b can be foldably connected (e.g., at a middle fold line 131as shown) to the second end corner panels 121 a, 123 a of the firstportion 100 a.

The first portion 100 a and the second portion 100 b can include aplurality of relief holes 133 placed to allow smooth folding of thecorner panels 117 a, b, 119 a, b, 121 a, b, 123 a, b, when forming theblank 200 into a suspension package insert 100. For example, the reliefholes 133 can be placed at locations where there are intersections offold lines connecting the panels of each portion 100 a, 100 b. As shown,opening 125 can be defined to perform the same function of relief holes133 for the corner panels 117 b, 119 b.

Referring to FIGS. 3A-3H, an embodiment of a process of folding andassembling a suspension packaging insert 100 from a blank 200 is shown.In FIG. 3A, the blank is unfolded. As shown in FIG. 3B, the firstportion 100 a can be folded the second portion 100 b. The side panels107 a, 107 b and side panels 109 a, 109 b can be connected together(e.g., via glue) such that a sandwich is made and the pouch 101 isformed between the first suspension panel 103 and the second suspensionpanel 105. Any other suitable panels can be connected at this portion ofthe process as well (e.g., end panels 113 a, b, and/or 115 a, b).Opening 125 creates an opening for an article to be inserted into thepouch 101.

As shown in FIGS. 3C and 3D, the end panels 113 a, b, and 115 a, b canbe folded over about 180 degrees. As shown in FIGS. 3E and 3F, the firstside panels 107 a, b and second side panels 109 a, b, can then be foldedup (e.g., above the first suspension panel 103 as shown) about 90degrees. The corner panels 117 a, b, 119 a, b, 121 a, b, 123 a, b, willall be folded inwardly at this point, e.g., as shown in FIG. 3F. Asshown in FIGS. 3F and 3G, the extension panels 127, 129 can be foldeddown over an outside of the respective side panels 107 b, 109 b about180 degrees to complete the formation of the sidewall structures 107,109. As shown in FIG. 3H, the insert 100 can then be placed in asuitable box with an article inside the pouch 100 (not shown).

Certain embodiments, e.g., as shown, can create sidewalls having adouble thickness above a bottom panel (e.g., second suspension panel105) which can be mostly rigid. In this regard, the double panelsidewalls will be positioned where the product would contact should theproduct contact the sidewalls, and thus the product can be moreprotected.

Any suitable adhesive can be applied to any suitable panel disclosedherein for any suitable purpose. Any suitable foldable line types arecontemplated herein (e.g., perforated, creased, cut/creased, etc.).While the figures may include a legend indicating the line types of theembodiments of the figures, any other suitable line types for the linesshown in the drawings are contemplated herein. While the figures mayinclude an embodiment of dimensions, any other suitable dimensions andrelative sized are contemplated herein. Any other suitable panelarrangement (e.g., more or less panels in any suitable location) iscontemplated herein.

While embodiments have been described and shown above, any suitablepanels and/or other design for a blank to form a device as disclosedabove is contemplated herein. Any suitable material for use (e.g.,paper, cardboard, plastic board, etc.) and/or one or more combinationsthereof are contemplated herein.

Embodiments can create an airspace under, over, and on all sides of aproduct. The pouch 101 can be defined by the suspension panels, and canbend, e.g., like a hammock. Such a system can maintain the articlesuspended in a box, for example. If the box tilts, the product can stayimmobilized in the suspension pouch 101. A rigidity of one or more ofthe suspension panels can be selected based on the size, weight, and/orshape of the article to be placed inside. In certain embodiments, ablank can be folded over and glued flat (e.g., as shown in FIG. 3B or 3Cand 3D), and shipped to a user in a flat, partially assembled state. Anyother suitable condition of the blank is contemplated herein.

Embodiments can include a folded insert that can form acustom/semi-flexible hammock, cocooning the product, surrounded by air,and enclosed. Embodiments can be used for a ship-receive-reshipcontainer and/or can be used for fragile “ship one” items. Any othersuitable use is contemplated herein. Certain embodiments can include anall fiber and/or renewable construction.

Those having ordinary skill in the art understand that any numericalvalues disclosed herein can be exact values or can be values within arange. Further, any terms of approximation (e.g., “about”,“approximately”, “around”) used in this disclosure can mean the statedvalue within a range. For example, in certain embodiments, the range canbe within (plus or minus) 20%, or within 10%, or within 5%, or within2%, or within any other suitable percentage or number as appreciated bythose having ordinary skill in the art (e.g., for known tolerance limitsor error ranges).

The articles “a”, “an”, and “the” as used herein and in the appendedclaims are used herein to refer to one or to more than one (i.e., to atleast one) of the grammatical object of the article unless the contextclearly indicates otherwise. By way of example, “an element” means oneelement or more than one element.

The phrase “and/or,” as used herein in the specification and in theclaims, should be understood to mean “either or both” of the elements soconjoined, i.e., elements that are conjunctively present in some casesand disjunctively present in other cases. Multiple elements listed with“and/or” should be construed in the same fashion, i.e., “one or more” ofthe elements so conjoined. Other elements may optionally be presentother than the elements specifically identified by the “and/or” clause,whether related or unrelated to those elements specifically identified.Thus, as a non-limiting example, a reference to “A and/or B”, when usedin conjunction with open-ended language such as “comprising” can refer,in one embodiment, to A only (optionally including elements other thanB); in another embodiment, to B only (optionally including elementsother than A); in yet another embodiment, to both A and B (optionallyincluding other elements); etc.

As used herein in the specification and in the claims, “or” should beunderstood to have the same meaning as “and/or” as defined above. Forexample, when separating items in a list, “or” or “and/or” shall beinterpreted as being inclusive, i.e., the inclusion of at least one, butalso including more than one, of a number or list of elements, and,optionally, additional unlisted items. Only terms clearly indicated tothe contrary, such as “only one of” or “exactly one of,” or, when usedin the claims, “consisting of,” will refer to the inclusion of exactlyone element of a number or list of elements. In general, the term “or”as used herein shall only be interpreted as indicating exclusivealternatives (i.e., “one or the other but not both”) when preceded byterms of exclusivity, such as “either,” “one of,” “only one of,” or“exactly one of.”

Any suitable combination(s) of any disclosed embodiments and/or anysuitable portion(s) thereof are contemplated herein as appreciated bythose having ordinary skill in the art in view of this disclosure.

The embodiments of the present disclosure, as described above and shownin the drawings, provide for improvement in the art to which theypertain. While the subject disclosure includes reference to certainembodiments, those skilled in the art will readily appreciate thatchanges and/or modifications may be made thereto without departing fromthe spirit and scope of the subject disclosure.

What is claimed is:
 1. A suspension package insert, comprising: asuspension pouch configured to receive an article therein, thesuspension pouch being formed of at least a first flexible suspensionpanel and a second suspension panel; a first sidewall structure attachedto a first side of the suspension pouch; and a second sidewall structureattached to a second side of the suspension pouch, wherein the first andsecond sidewall structures are configured to stand and suspend thesuspension pouch therebetween.
 2. The suspension package insert of claim1, wherein the first flexible suspension panel includes a cut matrixdefined therein configured to increase the flexibility of the firstflexible panel.
 3. The suspension package insert of claim 2, wherein thesecond suspension panel is uncut and/or is otherwise less flexible thanthe first flexible suspension panel.
 4. The suspension package insert ofclaim 1, wherein the suspension package insert is made of a fibermaterial.
 5. The suspension package insert of claim 4, wherein the fibermaterial is paper.
 6. A blank configured to form a suspension packageinsert of claim
 1. 7. A blank for a suspension package insert,comprising: a first portion; and a second portion foldably connected tothe first portion, wherein the first portion and the second portion areconfigured to be attached together to form a suspension pouch and asidewall assembly to suspend the suspension pouch.
 8. The blank of claim7, wherein the first portion includes a first flexible suspension panelhaving a cut matrix defined therein to increase a flexibility of thefirst flexible suspension panel.
 9. The blank of claim 8, wherein thefirst portion includes a first side panel and a second side panelfoldably connected to the first flexible suspension panel.
 10. The blankof claim 9, wherein the first portion includes a first end panel and asecond end panel foldably connected to the first flexible suspensionpanel.
 11. The blank of claim 10, wherein the first portion includes aplurality of first end corner panels and a plurality of second endcorner panels foldably connected to a respective end panel and arespective side panel.
 12. The blank of claim 11, wherein the secondportion includes a second suspension panel.
 13. The blank of claim 12,wherein the second portion includes a first side panel and a second sidepanel foldably connected to the second suspension panel.
 14. The blankof claim 13, wherein the second portion includes a first end panelconfigured to fold relative to the second suspension panel, and a secondend panel foldably connected to the second suspension panel.
 15. Theblank of claim 14, wherein the second portion includes an openingdisposed between the first end panel of the second portion and thesecond suspension panel.
 16. The blank of claim 15, wherein the secondportion includes a plurality of first end corner panels and second endcorner panels foldably connected to a respective end panel of the secondportion and a respective side panel of the second portion.
 17. The blankof claim 16, wherein the first end panel of the second portion isfoldably connected to the first and second side panels of the secondportion via the first end corner panels of the second portion.
 18. Theblank of claim 17, wherein the second portion includes a first extensionside panel foldably connected to the first side panel of the secondportion and a second extension side panel foldably connected to thesecond side panel of the second portion.
 19. The blank of claim 18,wherein the first and second extension side panels are each twice aswide as the first and second side panels of the second portion,respectively.
 20. The blank of claim 19, wherein the second end panel ofthe second portion is foldably connected to the second end panel of thefirst portion and/or wherein the second end corner panels of the secondportion are foldably connected to the second end corner panels of thefirst portion.